Melting pot



A. H. JUNG Dec. 3, 1940.

MELTING POT Filed April 28. 1939 3 Sheets-Sheet l maar Afm@ A. H. JUNGDec. 3, 1940.

MELTING POT I3 Sheets-Sheet 2 Filed April 28.' 1939.

' A. H. JUNG Dec. 3, 1940.

MELTING `POT Filed April 28, 1939 3 Sheets-Sheet 3 Patented Dec. 3, 1940Albert n. Jung, Flushing, N. Y., assignor to United American MetalsCorporation, Brooklyn, N. Y.,

a corporation of New York Application April 28, 1939, Serial No. 270,634

7 Claims.

Thisinvention relates to melting pots and more particularly to meltingpots capable of supplying molten `metal rapidly and economicallytofacilitate `the casting of relatively large quantities 5 thereoi'.4

Priortto the instant invention, melting pots have hadtheirburnersmorheating elements so associated therewith as to maintain the temperatureof the molten metal at a level generally corresponding to the castingtemperature and when relatively large -quantities of molten metal arecast, a measurable` period of time must elapse before `additional solidmetal may be `melted or fed to the pot and its state changed from asolid to u liquid, before additional metal may be used for casting.'I'his necessarytime delay associated with prior `constructions has beenfound to be costly as the labor and overhead which must be charged toeach casting is proportional to the 20 time involved in the fabricationof each casting.

Other prior constructions havelbeen designed to melt metal relativelyrapidly" but such constructions have been relatively large andnecessarily costly and further by reason `of their size Other objectsand the nature and advantages 35 of the invention will be apparent fromthe iol-l lowing description taken in conjunction with the` accompanyingdrawings, wherein:

Fig. 1 is a vertical section of a melting pot/*in A p accordance withthe invention;

Fig.2 is a top plan view of the embodiment of` [the inventionillustrated in Fig. 1, depicting the metal ingot being fed to themelting bath in section; Y

Fig. 3 is a sectional view taken along line 3-3 45 of Figi;

Fig. 4"is a fragmentary sectional view illustrating the flue and itsassociation with the furnace walls; and

Fig. 5 is a view similar to Fig. 1 but of a modi- 50 fied forni of theinvention;

Referring to the drawings the furnace IU comprises a refractory liningII and a cap I2 of material `which may or `may not be of refractorylsubstance but should be capable of withstanding u high temperature. TheAcombined melting pot I3 have been wasteful of fuel especially duringthose may be supported on this cap I2 by the integral flange vI4associated with the recess I5 and the cap I2. I n

-The combined melting pot I3 may include ,the relatively small capacity,but deep, high tem- .5 perature cavity I6 and a relatively largecapacity but shallow serving cavity Il. The two cavities may beconnected by the relatively small diameter integrally formed passage I 8which may be controlled-by the adjustable restrictior element I9 loassociated with its support in screw-threaded relation whereby it may beraised or lowered to effectincrease or decrease oftrestriction of thepassage I8.` l5

A heating element 2| is associated with the exterior of the `relativelyhigh temperature cavity I6 of the pot I3 and is depicted in Fig. 1 asbeing located directly therebelow. Depending from the under side of thetop wall of the pot I3 there is located between the cavity I6 and thecavity Il 2 a baffle member 22 cooperating with the'remain-` I ingstructure to prevent the direct passage of all the relativelyhot gasesemanatingirom the burner 2l to the exterior of the cavity I1.

Though the bafnezz extends from the top wall t of the pot, I3 completelyabout the connecting passage I8 and depends therefrom, it does notcontact` the `refractory lining Ilbut is spaced therefrom on threesides; namely, the.l bottom side 23, see Fig. 1, the side 24, and side25, see

`Fig. 2, to permit a predetermined proportion of the gases to flow aboutvthe exterior of the cavity I1 andV convey heat tothe molten metaltherewithin. 'I'hat portion of the refractory lining which is `adjacentto the cavity Il is built up to provide a predetermined hot gas passagesize thereabout.

' The 'gasburner--H is supplied with fuel through thepipe 26 which iscontrolled by electro-magnetic valve 2l which in turn receives itsenergy 40 from the source of current 28 when the switch 29 is in aclosed position. The switch 29 is in turn controlled by thethermo-couple 30 which through relay 3| affects the operation ofv thesame. The meter 32 mounted on the `panel 33 45 may visibly register thevtemperature of the molten metal in the bath 34 within the cavity Il andabout the thermo-couple 30.

As'the high temperature molten bath 35 communicates with the relativelylow temperature molten bath 34 'through the passage I8, under staticconditionsor substantially static condition, thev level within thecavity lI6 and Il will be substantially the same. As metal 'is removedfrom the serving cavity I1 the level therein willdrop 55 y'ns and thelevel within the cavity I6 will also drop. Associated with the hightemperature bath and directly above the cavity I6 is an ingot feedingmechanism 36 comprising a float 31 secured to the mechanism by chain 38.When the level within the molten bath 35 is lowered, the float 31 drops,pulling chain 3,8 and releasing the feeding mechanism 36 to lower thefeed hook h to which is attached the ingot 39 which may be of anysuitable typebut is depicted as being an automatic slip-off ingot.Lowering of the ingot 39 within the molten bath 35 effects the meltingthereof and the replenishment of the molten bath to raise its level andeffect a corresponding raising of the float 31 which slacks the chain 38to cause cessation of operation of the feeder mech` anism 36 until thelevel of molten metal is again owered, at which time the cycle abovedescribed s repeated.

As the cavity I1 is much larger than the cavity 6, see Fig. 2, thelowering of the level of' the ormer requires the melting of aconsiderable amount of `metal to effect its replenishment. To melt thenecessary amount of metal rapidly, the rnolten bath 35 is maintained ata higher temperature than the molten bath 34, which latter temperaturemay be generally corresponding to the casting temperature. For example,if the castingtemperatureis approximately 700 F., the temperature of themolten bath 34 may be maintained at that temperature whereas thetemperature of the molten bath 35 may be permitted t0 reach 900 F. oreven more. As the communi- :ating passage lv'connects the hightemperature bath 35 with the bottom of the lower temperature bath 34,the relatively high temperature molten metal passing to the molten bath34 must diffuse upwardly and therethrough and thereby prevent unduerising of temperature in any one portion of the molten bath 34.

Should the temperature of the molten bath tend to rise above apredetermined level of, for example, 2700 F., the thermo-couple 30 willcause the relay 3| tol close the switch 29 and permit electric currentAto flow from the source 28 to the electro-magnetic valve 21 to effectclosing the fuel line 26 and cause cessation of operation of the burner2| whereupon the temperature of.

the molten bath 35 will drop somewhat, whereby metal passing to themolten bath 34 through the communicating passage I8 will not transfer amaximum of heat to the bath 34 and further, there will be no ue gasesabout the exterior of the cavity I1 to transfer heat to the molten bath34. When the bath 34 requires additional heat to maintain theltemperature at the predetermined level which may be '700 F., thethermocouple 30 will be so actuated as to generate sufcient current tohold the switch 29 down against the action of the spring 3 I whereupontheV switch 29 will open and break the ilow of current from the Asource28 to the electro-magnetic valve 21V permitting the latter to fall openwhereupon the fuel will pass through the line 26 and will be ignited bypilot 40. Flue gases from the burner 2| pass in intimate contact withlthe exterior of the cavity I6` to maintain the temperature of themolten bath 36 substantially above that of the molten bath 34 and thenpasses about the baffle 22`along its sides 23, 24 and 25 to about theexterior of the cavity I1 and thence out the flue 4I. The flue 4| isarranged on the exterior of the furnace I0 but relatively` remote fromthe front 42 where the operator may stand and ladle molten metal fromthe cavity I1 as desired,

Not only is the construction of the melting pot I3 and the furnace I0such as to effect a higher temperature within the molten bath 35 thanwithin the molten bath 34, in order to permit rapid casting withoutdepleting the available molten metal, by effecting the rapid melting ofthe ingot'by feeding it to the high temperature bath, but the adjustingelement I9 is so aligned in association with the passage I8 as to slowdown the lowering of the level within the molten bath 35 even thoughthevflevel within the molten bath 34 is iowered rapidly corresponding torapid casting. This control of flow from the molten bath 35 to themolten bath 34 permits a relatively high level of hot metal within thebath 35 to be maintained effecting rapid melting of ingot 39 and themolten metal will be replenished before the level therein hasopportunity to be considerably lowered.

It will be understood from the above description that applicant hasprovided a melting pot system which may be relatively small in size buthigh in capacity and simultaneously economical of fuel whereby casting,or utilization of the molten metal produced, may be effectedrapidly.without interruption of the rapid melting of the metal in proportionscorresponding to the metal used to eflciently utilize the heat energyoperating to the device.

While the heating element associated with the metal furnace I0 has beendescribed as a gas burner, it isv to be undertsood that other heatingelements may be incorporated'in the furnace construction such as forexample an electric heater.` When an electric heater is utilized inplace of the burner 2 I, the control thereof is somewhat simpler as theelectro-magnetic valve 21 may be eliminated,`the source of current 28directly associated with the electric heater, and the control of thesource eifected by the switch 29 which is in turn controlled by thethermo-couple 30.

In certain casting processes in the field where an apparatus inaccordance with the instant invention is utilized; it is essential thatan additional burner be utilized in connection with the low temperaturecompartment of the two compartment melting pot. For example, where thecasting operations take place intermittently with relatively longperiods of time eiapsing between successive casting operations-the lowtemperature compartment may not receive enough heat" I compartment maynot receive enough heat, `or

if it does by reason of the fact that the thermocouple will make thesingle burner operate as long as the low temperature compartment doesnot have enough heat, the system willloperate inefciently. Accordingly,see Fig. 5, an additional burner |00 is provided in association with thecavity I1 and located within a well IOI within the refractory materialII and directly below the cavity I1.

The burner 2| is located below the cavity I6 in the same manner as'thatillustrated in Fig. l and serves to heat the molten metal within thesaid cavity. The pilot 40 cooperates with the burner 2| andthe pilot |02cooperates with c temperature within thelmolten bath I4, in..this uembodimentcf theinventionfit is controlledby i i respectively. ThemasterV switch the source of current lC and thev individual ,v

ao` ma the thermo-,couple T loatedrwithin `the molten bath andthetemperature of the'molten bath `34 is controlled bygthe thermo-coupleT'. The thermo-couples T and Tserve to control the switches S and Sthrough the medium of electro-magnets E and E', respectively. A sourceof current C serves to supply energy necessary to operate`electro-magnetic valves 21 and` |03, IM controls switches 105 Vand |08serve to operate the individual temperature control circuits ill'i and|08, respectively. `The remaining equipment and apparatus in thisembodiment to the invention is similar to `that described in connectionwith Figs. 1, 2 and 3.

`In operation, the molten baths 34 and 35 are intained within the sametemperature ranges as `described `in connection with the iirsternbodiment o1' the invention, but the Vcontrol is s effected by athermo-couple associated with` each cavity and in those instances inwhich such abnormal operationsr occur 'as to involve long f' periods oftime between successive casting operations, satisfactory eillciency willnevertheless result, the individualvmolten baths in the multi-V plecompartment, melting pot being maintained inthe proper temperatures andthe fuel consumption being relatively low,

Itwill be` obvious to those skilled in the art that various changes maybermade in this devvice without departing from thespirit of theinvention `and therefore the invention is not limited to what is shownin the ,drawings and described in'the specification but,` only asVindicated inthe appended claims.' i

What is` claimed is:

`1v. A melting and molten metal storage apparatus comprising: a furnacehaving a refractory lining, `a heating element in said furnace. a` shelladapted to hold molten metal supported by said furnace. said `shellincluding a pair of cavities. the first of lWhichiis located "directlyabove said heating element and the second of which is located in thepath of ilowloffhot gases from said heating element whereby it may beheated in- ,directly by said heating element, and means for 60controlling said heating element in response to the temperatureofnmolten` metal within said second cavity, said rst cavity beingadapted to have solid metal fed thereto and melted therein, andrestricted passage means i communicating 65 Vsaid cavities.

2. A melting pot comprising a `relatively high temperature bathadaptedto have solid metal fed thereto and melted therein.` and arelatively` low temperature bath adapted to have molten 70 metalwithdrawn therefrom, means for heating the relatively high temperaturebath, means for passing molten metal from said' high tempera ture bathinto the bottom of the relatively low temperature bath whereby the hotmolten metal 75 in said high temperature bath may serve to molten metalwithdrawn 4ed within said lining,

transfer heat to said low-temperature bath, and control means for Vsaidheating means responsive Y to the temperature oi' said low temperaturebath.

l compartment melting. pot includ- 'j ing `a relatively deep cavityaoi'small horizontal 1 section adaptedV to` have solid 3. A pluralmetal-lied thereto and melted therein, and a ity of great horizontalsection'adapted to have therefrom; heating means `directly associatedwith said deep cavity relatively shallow cavand indirectly associatedwith said shallow cavity,` means for passing molten metal'from said deepcavity into the bottom of saidshallow cav- 4. The structure recited inclaim l, and means for adjustably restricting said passage meanscommunicating said cavities. .f

5. A combined furnace and melting pot comprising a refractory lining,said refractory lining including a relatively small well, a burner insaid well, a pair of molten bath cavities suspendthe first of saidcavities being relatively small in horizontal section and locateddirectly above said burner, the second of said cavities being located ina vertical plane distinct from said ilrst cavity and said burner, meansfor passing molten material from said first cavltyinto the bottom ofsaid second cavity, baille means located between said two cavities andextending about said molten material passing means toward saidrefractory lining but being spaced therefrom to provide a restricted hotgas passage whereby hot gases from said burner may not only serve toheat said ilrst cavity but they may also heat said second cavity, meansresponsive to the temperature within said second cavity for controllingsaid heating element, and means responsive to the level of molten liquidin said first cavity for feeding solid metal thereto.

6. A metal melting apparatus comprising a plural compartment meltingpot, a rst of said compartments being relatively deep but small inhorizontal section. a second oi' said compartments being relativelyshallow and large in horizontal section, means for passing moltenmaterial from said first deep compartment into the bottom of said secondshallow compartment,`

means for restricting said passing means, `a heat-` ing element locateddirectly below said deep compartment for supplying a `relatively greatamount of heat thereto, restricting baflie means between said two`compartments and in association with said heating element whereby mostof the heat emanating from said heating element will be transmitted tosaid deep compartment, but some of said heat will be transmitted to saidshallow compartment. said baille means and said heat element tending tomaintain the temperature of said deep compartment higher than thetemper-v of small horizontal section and a second of said compartmentsbeing-relatively shallow but of large horizontal section, said firstcompartment being located substantially directly above said heatingelement, said rst compartment being generally circular in horizontalsection and said second -compartment being generally kidney shape inhorizontal section, `means for passing molten material from anintermediate portion of said deep compartment into the bottom of saidshallow compartment, baiile beans depending from the under side of thetop of said melting pot extending-about said communicating means on allsides and generally between said two com- Y partments in spaced relationthereto and vfur-- vther extending toward said refractory lining `'butspaced from said lining whereby said deep cavity will be in direct heatexchange relation with said heating element and said shallow cavity willreceive heat from said heating element indirectly from hot'gasespassing'rom the heating element perature range, and' means forfeedingsolid metal to said deepcompartmentfin accordance with the levelof, molten'liquid therein.

- ALBET H. JUNG.

